Load-bearing wall with header having a web frame

ABSTRACT

A load-bearing wall can be provided with a header comprising engineered wood web manufactured truss can be provided over the opening of the load-bearing wall. Insulation can be applied to the open areas of the truss to increase the thermal resistance of the header. The portion of the load-bearing wall can be constructed as a manufactured wall panel and incorporated with traditional stick framing. The manufactured wall panel can include straps to facilitate lifting, transporting and installation of the panels.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims a benefit of U.S. Provisional Patent application 62/358,088 filed Jul. 4, 2016, which is incorporated herein by reference herein for all purposes.

TECHNICAL FIELD

The present disclosure is related to the field of construction, in particular, wall panels used in the construction of buildings, the panels comprising web-framed headers used to bear loads over openings in load-bearing walls.

BACKGROUND

When constructing openings such as windows and doors in a load-bearing wall, a header is required over the opening to carry the load of the studs which are removed to accommodate the opening. Under traditional and current methods of construction, the headers used over window and door openings are either solid dimensional lumber or solid engineered wood product. With these methods of construction, the headers typically provide an insulation R-Value of no more than 6-7.5.

Additionally, using traditional stick building techniques, it can be difficult to achieve the tolerances in openings in the wall required by window and door manufacturers for the installation of a window or door in such an opening, particularly where construction is delayed due to adverse weather conditions.

It is, therefore, desirable to provide a load-bearing wall that overcomes the shortcomings of the prior art.

SUMMARY

A load-bearing wall with an opening is provided comprising a header to bear the load applied to the top portion of the wall above the opening. The use of an engineered wood web manufactured truss as a header can provide open areas within the web can permit insulation to be applied within the voids therein. Though the thermal bridge of the lumber portion of an engineered wood web manufactured truss can be similar to solid dimensional lumber or solid engineered wood products, insulation R-values of 20-25 can be provided when spray foam is applied to the open or void areas within the web structure of the truss.

The portion of a load-bearing with an opening can be incorporated into a manufactured wall panel. Using a manufactured wall panel for the portion of the wall with the opening can allow for the construction to be completed in a quality controlled environment off-site from where the building is being constructed. Constructing the openings in a manufactured wall panel in a controlled environment can enable the openings to be constructed to the correct tolerances in accordance with the manufacturer's specifications for the window or door being installed in the opening. The manufactured wall panel can be incorporated into traditional stick framing construction.

In some embodiments, the manufactured wall panel can also comprise straps that can facilitate lifting, transporting and installation of the panels. The straps can be positioned through open areas of the engineered wood web manufactured truss such that the straps do not interfere with the header plate on site, and can further allow the header plate to be incorporated and continuous with the remainder of the structure.

Broadly stated, in some embodiments, a load-bearing wall can be provided, the load-bearing wall comprising a header positioned above an opening for a door or a window, the header comprising a web frame, wherein the header is configured to bear the weight of a load applied to a top of the header, the web frame comprising at least one opening configured for receiving insulation therein.

Broadly stated, in some embodiments, a load-bearing wall panel can be provided, the wall panel comprising a header positioned above an opening for a door or a window, the header comprising a web frame, wherein the header is configured to bear the weight of a load applied to a top of the header, the web frame comprising at least one opening configured for receiving insulation therein.

Broadly stated, in some embodiments, a building structure can be provided comprising at least one load-bearing wall panel, the wall panel comprising a header positioned above an opening for a door or a window, the header comprising a web frame, wherein the header is configured to bear the weight of a load applied to a top of the header, the web frame comprising at least one opening configured for receiving insulation therein.

Broadly stated, in some embodiments, the web frame can comprise: an upper header plate defining a top of the web frame; a lower header plate disposed below the upper header plate defining a bottom of the web frame; a jack stud disposed on either side of the web frame; and one or both of at least one diagonal brace and at least one vertical brace disposed between the header plates and between the jack studs, the combination thereof defining the at least one opening.

Broadly stated, in some embodiments, the at least one opening can comprise insulation disposed therein.

Broadly stated, in some embodiments, the insulation can comprise spray foam insulation.

Broadly stated, in some embodiments, the engineered wood web manufactured truss can comprise insulation positioned in the open areas of the truss.

Broadly stated, in some embodiments, the load-bearing wall panel can further comprise at least one strap having opposing ends operatively coupled to the header, the at least one strap configured to lift and bear the weight of the wall panel.

Broadly stated, in some embodiments, one or both of the opposing ends can comprises a loop.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view depicting the interior side of a wall panel according to an embodiment of the wall panel described herein.

FIG. 2 is a perspective view depicting the wall panel of FIG. 1, showing the engineered wood web manufactured truss for the header thereof.

FIG. 3 is a close-up perspective view depicting the wall panel of FIG. 3, showing an embodiment of the strapping system.

FIG. 4 is a front perspective view depicting the wall panel of FIG. 1.

FIG. 5 is a close-up perspective view depicting the wall panel of FIG. 4.

FIG. 6 is a perspective view depicting a finished wall panel having the vapour barrier being removed from the opening in the wall panel.

FIG. 7 is a perspective view depicting the wall panel of FIG. 6 having shims placed for a window unit.

FIG. 8 is a perspective view depicting the wall panel of FIG. 7 with a window unit installed in the opening of the wall panel.

FIG. 9 is a perspective view depicting the wall panel of FIG. 8 having shims placed between the window unit and the sill plate of the wall panel opening.

FIG. 10 is a perspective view depicting the wall panel of FIG. 9 having the window unit secured to the wall panel.

FIG. 11 is a perspective view depicting the wall panel of FIG. 10 having spray foam insulation injected into the gap between the window unit and the opening of the wall panel.

FIG. 12 is an interior perspective view depicting the wall panel of FIG. 11 with the window unit installation completed.

FIG. 13 is an exterior perspective view depicting the wall panel of FIG. 12 with the window unit installation completed.

DETAILED DESCRIPTION OF EMBODIMENTS

When constructing load-bearing walls, it is necessary to include openings for windows and doors. Such openings require a header that bears the load applied over the opening in the wall.

Referring to FIGS. 1 to 3, opening 120 can be sized to accommodate the installation of a window, door or other required opening. The width of opening 120 can be sized as required by the desired use of the opening. Header 110 can be positioned above the opening such that any load applied to header plate 130 is transferred to jack studs 140. In some embodiments, header 110 can comprise an engineered wood web manufactured truss, which can comprise a web frame bounded by header plate 130 at the top, lower header plate 132 at the bottom and jack studs 140 on either side, with diagonal braces 112 and vertical brace 114 disposed therebetween to define a web structure with open areas 150 disposed between header plates 130 and 132, jack studs 140 and braces 112 and 114 as shown in FIGS. 1 to 3. In some embodiments, open areas 150 can have insulation 124 applied therein to increase the thermal resistance (R-value) of header 110. Insulation 124 can comprise spray foam insulation or other types of insulation known to one skilled in the art. Insulated header 110 can provide increased R-Values when compared to headers constructed from solid dimensional lumber or solid engineered wood products.

In some embodiments, header 110 can also be incorporated into a wall panel system. FIGS. 1 and 4 depict wall panel 100 with opening 120 disposed therethrough that can be sized to accommodate the installation of a window, door or other building component required for the structure. In some embodiments, wall panel 100 can incorporate header 110, which can further comprise an engineered wood web manufactured truss. Header 110 comprising an engineered wood web manufactured truss can have insulation 124 applied to open areas 150 to increase the insulation R-value of header 110. Insulation 124 can be applied at the time of manufacture of wall panel 100, or after wall panel 100 is installed on site.

In some embodiments, wall panel 100 can be manufactured in a quality controlled manufacturing environment. Construction of wall panel 100 in a quality controlled manufacturing environment can allow for the correct tolerances for opening 120 to be achieved, which can be in accordance with the window or door manufacturers' recommendation. FIGS. 6 to 13 show the installation of a window into opening 120 of wall panel 100. Traditional stick framing construction as known to one skilled in the art can be used around wall panel 100.

In some embodiments, wall panel 100 can comprise straps 160. FIG. 3 shows an embodiment of straps 160 incorporated into wall panel 100. Straps 160 can be constructed from a flexible material having opposing ends 162, 164. Ends 162, 164 can comprise loops or other suitable means of attaching straps 160 to a lifting mechanism. A lifting mechanism can include a crane, a forklift or other mechanism known to one skilled in the art. Straps 160 can be positioned around the underside of header plate 130 and pass through open areas 150 of header 110. The straps can allow for mechanical lifting of wall panel 100 for loading, unloading or installation on site. In some embodiments, straps 160 do not interfere with header plate 130 or sheathing 410 of wall panel 100. In some embodiments, one end of straps 160 can be sandwiched between header plate 130 and sheathing 410 so that sheathing 410 can be continuous with the rest of the structure. Once wall panel 100 has been installed in a structure, straps ends 162 and 164 can be cut off from wall panel 100.

Referring to FIG. 6, vapour barrier 170 is being removed from opening 120 of wall panel 100 in preparation for the installation of a window. Referring to FIG. 7, an installer is placing shim 180 required for the proper gap for the window above sill plate 122. Referring to FIG. 8, window unit 190 is being fitted into opening 120. Referring to FIG. 9, an additional shim 180 is being placed between window unit 190 and sill plate 122. In FIG. 10, window unit 190 is being secured to the front side of wall panel 100 with screws. In FIG. 11, spray foam insulation is being applied into gap 192 surrounding window unit 190 in opening 120. FIG. 12 shows a finished installation of window unit 190 in wall panel 100 from the interior side of the panel. FIG. 13 shows a finished installation of window unit 190 in wall panel 100 from the exterior side of the panel.

Although a few embodiments have been shown and described, it will be appreciated by those skilled in the art that various changes and modifications can be made to these embodiments without changing or departing from their scope, intent or functionality. The terms and expressions used in the preceding specification have been used herein as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding equivalents of the features shown and described or portions thereof, it being recognized that the invention is defined and limited only by the claims that follow. 

What is claimed is:
 1. A load-bearing wall, comprising a header positioned above an opening for a door or a window, the header comprising a web frame, wherein the header is configured to bear the weight of a load applied to a top of the header, the web frame comprising at least one opening configured for receiving insulation therein.
 2. The load-bearing wall as set forth in claim 1, wherein the web frame comprises: a) an upper header plate defining a top of the web frame; b) a lower header plate disposed below the upper header plate defining a bottom of the web frame; c) a jack stud disposed on either side of the web frame; and d) one or both of at least one diagonal brace and at least one vertical brace disposed between the header plates and between the jack studs, the combination thereof defining the at least one opening.
 3. The load-bearing wall as set forth in claim 1, further comprising insulation disposed in the at least one opening.
 4. The load-bearing wall as set forth in claim 3, wherein the insulation comprises spray foam insulation.
 5. A load-bearing wall panel, comprising a header positioned above an opening for a door or a window, the header comprising a web frame, wherein the header is configured to bear the weight of a load applied to a top of the header, the web frame comprising at least one opening configured for receiving insulation therein.
 6. The load-bearing wall panel as set forth in claim 5, wherein the web frame comprises: e) an upper header plate defining a top of the web frame; f) a lower header plate disposed below the upper header plate defining a bottom of the web frame; g) a jack stud disposed on either side of the web frame; and h) one or both of at least one diagonal brace and at least one vertical brace disposed between the header plates and between the jack studs, the combination thereof defining the at least one opening.
 7. The load-bearing wall panel as set forth in claim 5, further comprising insulation disposed in the at least one opening.
 8. The load-bearing wall panel as set forth in claim 7, wherein the insulation comprises spray foam insulation.
 9. The load-bearing wall panel as set forth in claim 5, further comprising at least one strap having opposing ends operatively coupled to the header, the at least one strap configured to lift and bear the weight of the wall panel.
 10. The load-bearing wall panel as set forth in claim 9, wherein one or both of the opposing ends comprises a loop.
 11. A building structure comprising at one load-bearing wall panel, the load-bearing wall panel comprising a header positioned above an opening for a door or a window, the header comprising a web frame, wherein the header is configured to bear the weight of a load applied to a top of the header, the web frame comprising at least one opening configured for receiving insulation therein.
 12. The building structure as set forth in claim 11, wherein the web frame comprises: i) an upper header plate defining a top of the web frame; j) a lower header plate disposed below the upper header plate defining a bottom of the web frame; k) a jack stud disposed on either side of the web frame; and l) one or both of at least one diagonal brace and at least one vertical brace disposed between the header plates and between the jack studs, the combination thereof defining the at least one opening.
 13. The building structure as set forth in claim 11, wherein the load-bearing wall panel further comprises insulation disposed in the at least one opening.
 14. The building structure as set forth in claim 13, wherein the insulation comprises spray foam insulation.
 15. The building structure as set forth in claim 11, wherein the load-bearing wall panel further comprises at least one strap having opposing ends operatively coupled to the header, the at least one strap configured to lift and bear the weight of the wall panel.
 16. The building structure as set forth in claim 15, wherein one or both of the opposing ends comprises a loop. 